Abstract: A system and method described herein detects the presence of an unconnected condition in high voltage component cables in an electric or hybrid-electric vehicle having a high voltage battery or energy storage system. The system includes a DC-DC converter which is capable of operating in either a step-down mode (e.g., as a buck converter) or a boost mode. The system uses the DC-DC converter operating in boost mode to create a sufficient, yet safe, measuring voltage on the main high voltage cabling of the vehicle before allowing the energy storage system to begin supplying high voltage power to the system components. The measurements are taken at various points near the individual components to determine if the cable has become disconnected.

Abstract: A system and method described herein detects the presence of an unconnected condition in high voltage component cables in an electric or hybrid-electric vehicle having a high voltage battery or energy storage system. The system includes a DC-DC converter which is capable of operating in either a step-down mode (e.g., as a buck converter) or a boost mode. The system uses the DC-DC converter operating in boost mode to create a sufficient, yet safe, measuring voltage on the main high voltage cabling of the vehicle before allowing the energy storage system to begin supplying high voltage power to the system components. The measurements are taken at various points near the individual components to determine if the cable has become disconnected.

Abstract: An electrical spring connection assembly electrically connects a conducting case, and a spark plug. The electrical spring connection assembly includes a base having a securing aperture for receiving the conducting case therein. The base fixedly secures the electrical spring connection assembly within the conducting case. The electrical spring connection assembly also includes a leaf spring portion that extends radially out from the base for receiving the spark plug therein. The leaf spring portion creates an engagement force the spark plug must overcome to be positioned within the electrical spring connection assembly. The electrical spring connection assembly also includes a beam spring portion extending out from the leaf spring portion. The beam spring portion creates a retention force to retain the spark plug within the electrical spring connection assembly. The retention force is greater than the engagement force.

Abstract: An ignition apparatus includes a secondary winding spool having a secondary winding wound thereon. The secondary winding includes a low voltage end and a high voltage end that is configured for connection to a spark plug. The secondary winding at the high voltage end is configured in accordance with a predetermined radial thickness profile taken in the direction from the high voltage end towards the low voltage end. The profile is determined as a function of (1) a reflected voltage associated with the spark gap breakdown of the spark plug and (2) an induced voltage due to magnetic flux coupled through a central core. The profile is determined so as to reduce layer-to-layer voltage levels in the secondary winding near the high voltage end. The profile can be wound or can be molded in the secondary spool itself.

Abstract: Method for introducing encapsulating material into an ignition coil including a primary winding, a secondary winding and a secondary spool is provided. The method allows providing a fluid-directing device at a first end of the secondary spool. The method further allows providing flow communication between the fluid-directing device and a first channel defined between the outer diameter of the primary winding and the inner diameter of the secondary spool. Flow communication is provided between the first channel and a second channel at a distal end from the first end. The second channel defined between the outer diameter of the secondary winding and the housing of the ignition coil. Encapsulating material (either pressurized or non-pressurized) is introduced through the fluid-directing device for generally downwardly flow into the first channel.

Abstract: An ignition apparatus includes a high voltage (HV) terminal formed of stamped sheet metal configured to be disposed in a secondary winding spool, and to which a high voltage end of the secondary winding is attached and soldered. The ignition apparatus further includes an electrically conductive cup configured to surround the high voltage terminal when the secondary winding spool is inserted in the case. The high voltage terminal has one end that comes into engagement with an inner annular surface of the cup. The cup includes an annular sidewall that extends axially up to a winding flange where a HV end of the secondary winding exits a winding bay thereby surrunding the exiting HV secondary winding wire. The cup provides for a reduced electric field concentration.

Abstract: An ignition coil for a spark ignition internal combustion engine has a central core. The central core is cylindrical in shape, and includes a plurality of laminations composed of magnetically-permeable plates that are sector-shaped. The sector-shaped laminations improve the fill percentage allotted for core material. The central core has a central bore extending therethrough that allows a return of a primary winding lead, allowing an odd number of primary winding layers.

Abstract: An ignition coil (10) has a core (16) composed of a plurality of laminations (46) and about which is directly disposed an insulating layer (22). A primary winding (24) is wound directly on the insulating layer (22), thereby eliminating the need for a primary winding spool and recovering the space conventionally occupied by such a primary winding spool for use in allocating greater space to the core (16) and/or windings.

Abstract: A coil winding system is provided for making a secondary winding for an automotive ignition coil. The system includes a roller configured to apply a holding force to wire being dispensed from a wire nozzle onto a bobbin. The nozzle and roller are moved by a drive mechanism under control of a controller from one axial end to the other axial end of the bobbin for winding the bobbin in a progressive winding fashion. The roller allows an increase in the winding angle of the layers, which reduces the voltage difference between adjacent layers, thereby reducing incidence of dielectric break down in that region.

Abstract: A method for inhibiting or eliminating case erosion in a pencil ignition coil having an internal primary winding and an external secondary winding and shield. Three alternative means for resisting damage due to the partial discharge phenomenon arising from a high electric field in such coil configurations are provided: (i) applying an ozone resistant coating on the case; (ii) applying a coating on the case for eliminating partial discharge under the shield; and (iii) applying a polyimide tape covering to the case for resisting partial discharge under the shield.

Abstract: A method and apparatus for securing at least one ignition coil to an ignition coil cassette, the ignition coil cassette having a main body portion being adapted to receive and engage a plurality of coils for generating a high voltage signal to be received by a spark plug of an internal combustion engine. The coils being ultrasonically welded to the main body portion of the ignition coil cassette. The coils being secured in a manner which correctly positions the coils in an appropriate location as well as providing a rigid securement of the coil to the main body portion.

Abstract: An ignition coil is provided for an internal combustion engine. The ignition coil comprises a primary winding and a secondary winding. The primary winding is adapted to be electrically connected to a low-voltage ignition signal. The secondary winding is inductively coupled to the primary winding with more turns than the primary winding so that the secondary winding develops a high-voltage ignition signal in response to switching of the low-voltage ignition signal. The turns of the secondary winding are provided in successive layers. An uncured material is applied to the secondary winding prior to the placement of the successive layers. By using an uncured stage material, the coil can be made without the need for complex, expensive, time-consuming, and potentially unreliable impregnation techniques. The ignition coil can be used as a pencil coil for spark plugs of an internal combustion engine. Also provided is a method of manufacturing an ignition coil.

Abstract: A printed circuit board (PCB) for an ignition apparatus includes a connection interface. The connection interface includes a first hole, and a second hole that is smaller than the first hole. The second hole has a pad associated therewith that is electrically coupled to a conductive trace for connecting to a system connector. The first hole and the second hole are coupled by way of a channel. The first hole is sized so as to facilitate insertion of a winding end, while the second hole is configured to facilitate a soldering operation of the winding end to the pad. The channel width is less than the diameter of the winding end so that once the winding end is in the smaller hole, the channel provides, in-effect, a retaining feature until it can be soldered.

Abstract: A method for inhibiting or eliminating case erosion in a pencil ignition coil having an internal primary winding and an external secondary winding and shield. Three alternative means for resisting damage due to the partial discharge phenomenon arising from a high electric field in such coil configurations are provided: (i) applying an ozone resistant coating on the case; (ii) applying a coating on the case for eliminating partial discharge under the shield; and (iii) applying a polyimide tape covering to the case for resisting partial discharge under the shield.

Abstract: An ignition apparatus includes a high voltage (HV) terminal formed of stamped sheet metal configured to be disposed in a secondary winding spool, and to which a high voltage end of the secondary winding is attached and soldered. The ignition apparatus further includes an electrically conductive cup configured to surround the high voltage terminal when the secondary winding spool is inserted in the case. The high voltage terminal has one end that comes into engagement with an inner annular surface of the cup. The cup includes an annular sidewall that extends axially up to a winding flange where a HV end of the secondary winding exits a winding bay thereby surrunding the exiting HV secondary winding wire. The cup provides for a reduced electric field concentration.

Abstract: A method and apparatus for securing at least one ignition coil to an ignition coil cassette, the ignition coil cassette having a main body portion being adapted to receive and engage a plurality of coils for generating a high voltage signal to be received by a spark plug of an internal combustion engine. The coils being ultrasonically welded to the main body portion of the ignition coil cassette. The coils being secured in a manner which correctly positions the coils in an appropriate location as well as providing a rigid securement of the coil to the main body portion.

Abstract: An ignition apparatus includes a magnetic circuit comprising a central core and a side core or shield, and primary and secondary windings. The shield is allowed to electrically float, thereby reducing the capacitance of the secondary winding. A housing is external to and surrounds the shield to inhibit arcing. A silicone boot overlaps a housing/case interface to further suppress arcing.

Abstract: An ignition apparatus includes a magnetic circuit comprising a central core and a side core or shield, and primary and secondary windings. The shield is allowed to electrically float, thereby reducing the capacitance of the secondary winding. A unitary boot surrounds the shield to inhibit arcing, and further includes a seal configured to seal a spark plug well or the like.

Abstract: An ignition coil (10) has a core (16) composed of a plurality of laminations (46) and about which is directly disposed an insulating layer (22). A primary winding (24) is wound directly on the insulating layer (22), thereby eliminating the need for a primary winding spool and recovering the space conventionally occupied by such a primary winding spool for use in allocating greater space to the core (16) and/or windings.

Abstract: An interface device for interfacing a pencil coil to a spark plug is provided. The interface device comprises a substantially C-shaped spring adapted to mechanically and electrically engage a pencil coil shield and also adapted to make electrical contact with a spark plug ground while the spring remains mechanically and electrically engaged to the pencil coil shield. Also provided is a pencil coil shield assembly for interfacing a pencil coil to a spark plug. The pencil coil shield assembly comprises a substantially cylindrical pencil coil and a spring. The substantially cylindrical pencil coil shield is adapted to surround the pencil coil. The spring is mechanically and electrically engaged with the pencil coil shield and is adapted to make electrical contact with a spark plug ground while the spring remains mechanically and electrically engaged to the pencil coil shield.